Casing Debris Cleaner

ABSTRACT

A downhole tool cleans debris from a subsea well with nozzle assemblies that selectively deploy from the tool. The nozzle assemblies are in fluid communication with an annulus of a drill pipe on which the downhole tool is mounted, so that fluid pumped into the drill pipe discharges from nozzles provided with the nozzle assemblies. The nozzle assemblies are strategically situated so that when deployed, a stream discharged from nozzles on the assemblies clears debris from a surface between a casing hanger and wellhead housing. The nozzle assemblies are coupled to an annular piston coaxially set on the tool; and sliding the piston axially along the tool deploys the nozzle assemblies. Axially spaced apart ports extend radially through the tool to opposing faces on a head of the piston. Blocking one of the ports with a ball dropped down the drill pipe moves the piston and deploys the assemblies.

BACKGROUND

1. Field of Invention

The present disclosure relates in general to a device for use in completing a wellbore. More specifically, the present disclosure relates to a device for removing debris from a casing hanger prior to setting a seal between the casing hanger and wellhead housing.

2. Description of Prior Art

Subsea wells typically include a wellhead assembly with a wellhead housing that anchors on the subsea floor. Concentric strings of casing and tubing depend into the well and are supported by the wellhead housing. A tubular casing hanger is usually employed for mounting the casing string within the wellhead housing, where an upper end of the string threads onto the hanger. The casing hanger typically lands on a landing shoulder in the wellhead, or on a previously installed casing hanger having larger diameter casing. Cement is pumped down the string of casing to flow back up the annulus around the string of casing.

Seals are typically installed between concentric wellhead tubular members to contain internal well pressure. One of the tubulars often includes a shoulder that radially projects towards the other tubular and defines a landing platform or support for a seal. Because the shoulder is usually exposed to well fluids during completion of the well, debris can collect or be deposited on the shoulder. The presence of debris on the shoulder can compromise seal integrity.

SUMMARY OF THE INVENTION

Described herein is an example of a downhole tool for cleaning debris from a subsea well that includes a tool body having an axial bore, a nozzle assembly on the tool body having a discharge end in selective fluid communication with the bore in the tool body, a piston selectively movable axially along the tool body, and a deployment system. In this example the deployment system is made up of an elongated member that is coupled to the tool body by a pivoting connection. The elongated member also pivotingly connects to the piston and the nozzle assembly. When the piston axially slides along the tool body, the elongated member pivots about the tool body and repositions the nozzle assembly radially outward from the tool body. The downhole tool can further include an upper port in the tool body that extends radially outward from the axial bore and a lower port in the tool body that extends radially outward from the axial bore and that is spaced axially away from the upper port. In one example, the piston has a face in fluid communication with the upper port and an opposing face in selective fluid communication with the lower port, so that when fluid communication is blocked between the opposing face and lower port, the piston axially slides along the tool body. In this example, a radius of the axial bore decreases to define a shoulder adjacent the lower port that is strategically profiled to selectively receive a ball for blocking fluid communication between the axial bore and the lower port. The elongated member can be a first elongated member, and the deployment system further includes a second elongated member having end portions respectively pivotingly attached to the piston and the nozzle assembly and a middle portion pivotingly attached to a middle portion of the first elongated member. Optionally, the deployment system and nozzle assembly are strategically dimensioned so that when the tool body is inserted into a casing hanger coaxially disposed in a wellhead housing, a cleaning stream discharged from the nozzle assembly is directed into an annulus between the casing hanger and wellhead housing for cleaning debris from within the annulus. An outer groove may optionally be included along an axial portion the tool body that projects radially inward from an outer circumference of the tool body, and an inner groove may also be provided that projects radially inward from the outer groove. In this example the piston includes a tubular body that is axially slidable in the outer groove, and a ring like head projecting radially inward from the tubular body and axially slidable in the inner groove.

Also disclosed herein is a downhole tool for use in forming a wellhead assembly subsea that is made from an annular tool body with an axial bore, an upper port extending radially through the tool body, and a lower port extending radially through the tool body, a piston mounted on the tool body having a face in fluid communication with the upper port and an opposing face in selective fluid communication with the lower port. Also included with this downhole tool is a nozzle assembly that has a flow line whose inlet is in fluid communication with the upper port and an exit, where the nozzle assembly is selectively movable from a running position stowed adjacent the tool body to a deployed position, so that the exit is directed to a designated area in the wellhead assembly. The downhole tool can further have a deployment means for deploying the nozzle assembly from the running position to the deployed position. In this example, the deployment means is an elongated member having am end portion pivotingly attached to the tool body, a distal end portion pivotingly attached to the nozzle assembly, and a middle portion coupled with the piston, so that when pressurized fluid is provided to the axial bore while fluid communication between the axial bore and lower port is blocked, pressurized fluid flows through the upper port to the face to axially move the piston thereby rotating the elongated member and urging the nozzle assembly into the deployed position. Further in this example, the elongated member is a first elongated member, and the deployment means further includes a second elongated member having end portions pivotingly connected respectively to the piston and the nozzle assembly and a middle portion pivotingly attached to a middle portion of the first elongated member. In one example, the lower port is axially displaced from the upper port and wherein the axial bore narrows adjacent the lower port to define a shoulder configured so that when a ball is set on the shoulder, the ball blocks fluid communication between the axial bore and the lower port. Optionally, the deployment system and nozzle assembly are strategically dimensioned so that when the tool body is inserted into a casing hanger coaxially disposed in a wellhead housing, a cleaning stream discharged from the nozzle assembly is directed into an annulus between the casing hanger and wellhead housing for cleaning debris from within the annulus. The downhole tool may optionally include an outer groove along an axial portion the tool body that projects radially inward from an outer circumference of the tool body, and an inner groove that projects radially inward from the outer groove and wherein the piston comprises a tubular body that is axially slidable in the outer groove, and a ring like head projecting radially inward from the tubular body and axially slidable in the inner groove. In this example, the head is disposed between the upper and lower ports when the nozzle assembly is in the running position, and is moved to adjacent the lower port when the nozzle assembly is in the deployed position. Connections are optionally included at upper and lower ends of the tool body for connection to a drill string.

An example of a method of clearing debris from an annulus between a casing hanger and a wellhead housing is disclosed that includes providing a cleaning tool having a body, an axial bore, a nozzle assembly mounted on the tool body that is in fluid communication with the axial bore, and a deployment means for positioning the nozzle assembly into a cleaning position and coupling the cleaning tool within a tool string having an annulus that registers with the axial bore. The method also includes inserting the tool string into the casing hanger, pressurizing axial bore by flowing pressurized fluid into the annulus, deploying the nozzle assembly by selectively providing fluid communication between the axial bore and the deployment means so that a discharge end of the nozzle assembly is directed between the casing hanger and the wellhead housing, and cleaning an area between the casing hanger and wellhead housing by discharging pressurized fluid from the discharge end of the nozzle.

BRIEF DESCRIPTION OF DRAWINGS

Some of the features and benefits of the present invention having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, in which:

FIG. 1 is a side sectional view of an example embodiment of a debris cleaner in accordance with the present invention.

FIG. 2 is a side sectional view of the debris cleaner of FIG. 1 being deployed adjacent a casing hanger in accordance with the present invention.

While the invention will be described in connection with the preferred embodiments, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION OF INVENTION

The method and system of the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings in which embodiments are shown. The method and system of the present disclosure may be in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey its scope to those skilled in the art. Like numbers refer to like elements throughout.

It is to be further understood that the scope of the present disclosure is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. In the drawings and specification, there have been disclosed illustrative embodiments and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation.

Shown in a side sectional view in FIG. 1 is an example of a tool string 10 that includes a debris cleaner 12 coaxially mounted in a string of drill pipe 14. In the example of FIG. 1, the drill pipe 14 depends downward from a lower end of the debris cleaner 12 and inserts into a casing hanger 16 shown mounted on the sea floor 17. Also mounted in the sea floor 17 is a wellhead housing 18 shown circumscribing the casing hanger 16. A riser (not shown) may mount on the wellhead housing 18 and provide a conduit for inserting the tool string 10 within as the tool string 10 is lowered subsea.

Debris cleaner 12 is shown including an annular lower body 20 whose lower portion is configured into a pin end 22 that threadingly connects to a box end 24 on an upper end of the drill pipe 14. An upper body 26 coaxially mounts onto the lower body 20 on an end opposite the drill pipe 14, and similarly includes a pin end 28 on its lower end that threadingly attaches to a box end 30 formed on an upper end of the lower body 20. An axial bore 32 is shown extending through the drill pipe 14, lower body 20, and upper body 26.

Nozzle assemblies 34 are provided with the debris cleaner 12, which are shown in a running position in FIG. 1 disposed adjacent to the lower and upper bodies 20, 26. In the example of FIG. 1, the nozzle assemblies 34 are elongate members having an end coupled on the debris cleaner 12, and a distal portion provided with a nozzle 35 from which a cleaning fluid stream is discharged (FIG. 2). A deployment means is provided for selectively deploying the nozzle assemblies 34 outward from the debris cleaner 12. In an example the deployment means includes a scissor connection 36 that is made up of an elongated arm 38 having one end coupled to the lower body by a pinned connection 40, so that the arm 38 can pivot about the connection 40 and rotate with respect to the lower body 20. An end of arm 38 distal from pinned connection 40 is connected to the nozzle assembly 34 by pinned connection 42, so that the arm 38 can pivot about the connection 42 and rotate with respect to the nozzle assembly 34. In the example of FIG. 1, the pinned connection 42 mounts onto a housing 43 that covers a portion of the nozzle assembly 34. Shown in a mid portion of the arm 38 is a pinned connection 44 that pivotingly connects the arm 38 to another arm 46. Arm 46 has an end mounted onto the housing 43 by pinned connection 48, so that arm 46 can rotate with respect to the nozzle assembly 34 and about pinned connection 48. On an end of arm 46 distal from pinned connection 48 a pinned connection 50 that pivotingly mounts arm 46 to a piston 54 shown circumscribing a portion of the upper end lower bodies 26, 20. As described in more detail below, the piston 54 is also part of the deployment means for deploying the nozzle assemblies 34.

An outer circumference of the piston 52 defines a generally tubular shaped body 54, and the inner circumference of the piston 52 includes a head 56 that projects radially inward from the body 54. In the example of FIG. 1, the head 54 is at about an axial mid portion of the body 54, but embodiments exist where the head 54 could be axially offset from the mid portion. An outer groove 58 is illustrated that is formed along the circumference of the debris cleaner 12 and extending axially across the interface where the lower and upper bodies 20, 26 are joined. An inner groove 60 is shown in the upper body 26 that projects radially inward from a portion of the outer groove 58. The inner groove 60 can be at about a mid portion of the outer groove 58, or offset therefrom. In the example of FIG. 1, the outer groove 58 is dimensioned so that the piston body 54 may axially slide therein, and similarly the inner groove 60 is dimensioned to receive the piston head 56 therein and allow the piston head 56 to slide an axial distance therein. In the example of FIG. 1, the piston 52 is biased upward by a spring 62 so that the upper end of the piston body 54 contacts a lower facing end of the upper groove 58 and the upper end of the piston head 54 contacts a lower facing surface of inner groove 60.

Still referring to FIG. 1, an upper port 64 is shown projecting radially outward through the upper body 26 and from the bore 32 and to the inner groove 60. Thus, upper port 64 provides fluid communication between bore 32 and upper face 65 that is defined by a lateral upward facing side of the piston head 54. Further illustrated in FIG. 1 is a lower port 66 that projects radially outward from the bore 32 into the inner groove 60 therefore providing fluid communication between the bore 32 and a lower face 67, which is defined by a lower facing lateral surface of the piston head 54. In the example of FIG. 1, ports 64, 66 are both open so that fluid pressure in the bore 32 is exerted substantially equally along upper face 65 and lower face 67 thereby equalizing pressure forces on piston 52. The pressure equalization, in addition to the upwardly biasing force of spring 62, retains the piston 52 in its illustrated position. Radius of the bore 32 projects radially inward in the region between ports 64, 66 and defines an upward facing shoulder 68. The shoulder 68 is configured to receive a ball 70 thereon and as will be described in more detail below, provides a means for positioning the nozzle assemblies 34 into a deployed configuration.

Referring now to FIG. 2, the debris cleaner 12 is shown in a deployed configuration for cleaning a space between the facing hanger 16 and wellhead housing 18. As shown, the ball 70 is landed in shoulder 68 (or seat) so that by pressuring the portion of the bore 32 above the ball 70, a pressure differential can be created across the piston head 56 due to differing pressures applied to the upper and lower faces 65, 67. For example, the ball 70 blocks fluid communication from pressurized fluid in the bore 32 and into port 66. However, pressurized fluid is allowed to enter into the inner groove 60 via port 64, as increasing pressure in upper port 64 exceeds pressure in lower port 66. The piston 52 is urged downward so that the lower end of the piston body 54 contacts a lower end of the outer groove 58, and lower face 67 contacts an upper terminal end of the inner groove 60. By downwardly moving piston 52, arms 38, 46 are rotated about their respective pinned connections 40, 42, 44, 48 drawing pinned connections 40, 50 axially more proximate and projecting ends of the arms 38, 46 having pinned connections 42, 48 radially outward from the bodies 20, 26. As the housing 43 mounts to the bodies 20, 26 on the ends of the arms 38, 46 having pinned connections 42, 48, housing 43 is urged radially outward from the 20, 26.

As shown, the nozzle assemblies 34 include a flexible hose 72 having one end that inserts within an upper end of housing 43, and another end coupled to an outer surface of the piston body 54. Hose 72 is in fluid communication with fluid in the inner groove 60 via a passage 74 that extends through the piston body 54. Strategic dimensioning of the arms 38, 46 and nozzle assemblies 34 sets the nozzles 35 in an annular space 76 between the casing hanger 16 and wellhead housing 18 when the nozzle assemblies 34 are in the deployed position. As shown, a stream exiting the nozzle 34 can be directed to a shoulder 78 or ledge on the casing hanger 16 so that debris 80 collected on the shoulder 78 may be washed away with fluid being discharged from the nozzle 35. Further in the example of FIG. 2, the fluid supplied for cleaning in the annular space 76 is pressurized fluid in the bore 32 above ball 72, where the pressurized fluid flows through the upper port 64, inner groove 60, and hose 72 prior to being discharged from the nozzles 35. Optionally, slots 82 are provided in the housing 43 so that pinned connection 48 can slide axially along housing 43 during steps of deploying the nozzle assemblies 34 and when being stowed back onto the debris cleaner 12 and into the running position of FIG. 1. An optional method of deployment includes setting the debris cleaner 12 on a lower end of drill pipe 84, threaded connections between drill pipe 84 and upper end of upper body 26 are illustrated.

The present invention described herein, therefore, is well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent therein. While a presently preferred embodiment of the invention has been given for purposes of disclosure, numerous changes exist in the details of procedures for accomplishing the desired results. These and other similar modifications will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the present invention disclosed herein and the scope of the appended claims. 

What is claimed is:
 1. A downhole tool for cleaning debris from a subsea well comprising: a tool body having an axial bore; a nozzle assembly on the tool body having a discharge end in selective fluid communication with the bore in the tool body; a piston selectively movable axially along the tool body; and a deployment system comprising an elongated member pivotingly coupled to the tool body, the piston, and the nozzle assembly, so that when the piston axially slides along the tool body, the elongated member pivots about the tool body and repositions the nozzle assembly radially outward from the tool body.
 2. The downhole tool of claim 1, further comprising an upper port in the tool body that extends radially outward from the axial bore and a lower port in the tool body that extends radially outward from the axial bore and that is spaced axially away from the upper port.
 3. The downhole tool of claim 2, wherein the piston has a face in fluid communication with the upper port and an opposing face in selective fluid communication with the lower port, so that when fluid communication is blocked between the opposing face and lower port, the piston axially slides along the tool body.
 4. The downhole tool of claim 3, wherein a radius of the axial bore decreases to define a shoulder adjacent the lower port that is strategically profiled to selectively receive a ball for blocking fluid communication between the axial bore and the lower port.
 5. The downhole tool of claim 1, wherein the elongated member comprises a first elongated member and the deployment system further comprises a second elongated member having end portions respectively pivotingly attached to the piston and the nozzle assembly and a middle portion pivotingly attached to a middle portion of the first elongated member.
 6. The downhole tool of claim 1, wherein the deployment system and nozzle assembly are strategically dimensioned so that when the tool body is inserted into a casing hanger coaxially disposed in a wellhead housing, a cleaning stream discharged from the nozzle assembly is directed into an annulus between the casing hanger and wellhead housing for cleaning debris from within the annulus.
 7. The downhole tool of claim 1, further comprising an outer groove along an axial portion the tool body that projects radially inward from an outer circumference of the tool body, and an inner groove that projects radially inward from the outer groove and wherein the piston comprises a tubular body that is axially slidable in the outer groove, and a ring like head projecting radially inward from the tubular body and axially slidable in the inner groove.
 8. A downhole tool for use in forming a wellhead assembly subsea comprising: an annular tool body having an axial bore, an upper port extending radially through the tool body, and a lower port extending radially through the tool body; a piston mounted on the tool body having a face in fluid communication with the upper port and an opposing face in selective fluid communication with the lower port; and a nozzle assembly selectively movable from a running position stowed adjacent the tool body to a deployed position and that comprises a flow line having an inlet in fluid communication with the upper port and an exit, so that the exit is directed to a designated area in the wellhead assembly.
 9. The downhole tool of claim 8, further comprising a deployment means for deploying the nozzle assembly from the running position to the deployed position.
 10. The downhole tool of claim 9, wherein the deployment means comprises an elongated member having an end portion pivotingly attached to the tool body, a distal end portion pivotingly attached to the nozzle assembly, and a middle portion coupled with the piston, so that when pressurized fluid is provided to the axial bore while fluid communication between the axial bore and lower port is blocked, pressurized fluid flows through the upper port to the face to axially move the piston thereby rotating the elongated member and urging the nozzle assembly into the deployed position.
 11. The downhole tool of claim 10, wherein the elongated member comprises a first elongated member, the deployment means further comprising a second elongated member having end portions pivotingly connected respectively to the piston and the nozzle assembly and a middle portion pivotingly attached to a middle portion of the first elongated member.
 12. The downhole tool of claim 8, wherein the lower port is axially displaced from the upper port and wherein the axial bore narrows adjacent the lower port to define a shoulder configured so that when a ball is set on the shoulder, the ball blocks fluid communication between the axial bore and the lower port.
 13. The downhole tool of claim 8, wherein the deployment system and nozzle assembly are strategically dimensioned so that when the tool body is inserted into a casing hanger coaxially disposed in a wellhead housing, a cleaning stream discharged from the nozzle assembly is directed into an annulus between the casing hanger and wellhead housing for cleaning debris from within the annulus.
 14. The downhole tool of claim 8, further comprising an outer groove along an axial portion the tool body that projects radially inward from an outer circumference of the tool body, and an inner groove that projects radially inward from the outer groove and wherein the piston comprises a tubular body that is axially slidable in the outer groove, and a ring like head projecting radially inward from the tubular body and axially slidable in the inner groove.
 15. The downhole tool of claim 14, wherein the head is disposed between the upper and lower ports when the nozzle assembly is in the running position, and is moved to adjacent the lower port when the nozzle assembly is in the deployed position.
 16. The downhole tool of claim 8, further comprising connections at upper and lower ends of the tool body for connection to a drill string.
 17. A method of clearing debris from an annulus between a casing hanger and a wellhead housing comprising: providing a cleaning tool having a body, an axial bore, a nozzle assembly mounted on the tool body that is in fluid communication with the axial bore, and a deployment means for positioning the nozzle assembly into a cleaning position; coupling the cleaning tool within a tool string having an annulus that registers with the axial bore; inserting the tool string into the casing hanger; pressurizing axial bore by flowing pressurized fluid into the annulus; deploying the nozzle assembly by selectively providing fluid communication between the axial bore and the deployment means so that a discharge end of the nozzle assembly is directed between the casing hanger and the wellhead housing; and cleaning an area between the casing hanger and wellhead housing by discharging pressurized fluid from the discharge end of the nozzle. 